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Stihl TS 410, TS 420 Super Cut Saws & Parts Workshop Service Repair Manual

Stihl TS 410, TS 420 Super Cut Saws & Parts Workshop Service Repair Manual

Stihl Cut-Off Saws TS 410, TS 420 Super Cut Saws Service Repair Manual & Parts manual

This Stihl TS 410, TS 420 service manual contains detailed descriptions of all the typical repair and servicing procedures for this power tool. Refer to the illustrated spare parts lists during all repair work. These lists show the installation position and order in which the individual parts and modules should be assembled. Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts required. A fault on the machine may be due to several causes. To help locate the fault, consult the chapter on “Troubleshooting” and the “STIHL Service Training System” for all function groups. Refer to the “Technical Information” bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list and service manual until an updated edition is issued. The special tools mentioned in the descriptions are listed in the chapter “Special Servicing Tools” of this manual. Use the part numbers to identify the tools in the STIHL Special Tools manual. It lists all the special servicing tools currently available from STIHL.

Stihl TS 410 TS 420 Super Cut Saws & Parts

Stihl TS 410 TS 420 Super Cut Saws & Parts

TS410-TS420 Service Manual

This Manual Covers

1. Introduction G3.9555
2. Safety precautions G3.9678
3. Specifications G4.851891
3.1 Shortblock G4.851896
3.2 Fuel system G4.851531
3.3 Ignition system G4.851597
3.4 Cutting wheels G4.851659
3.5 Tightening torques G5.768582
4. Troubleshooting G6.130896
4.1 Clutch G6.130901
4.2 Cast arm with guard G7.781116
4.3 Rewind starter G8.646057
4.4 Ignition system G9.82914
4.5 Carburetor G10.1030643
4.6 Engine G11.123499
5. Cast arm with guard G12.827753
5.1 Water system G12.827759
5.2 Cast arm with guard G12.827913
5.3 Testing radial and axial truth of running G12.828420
5.4 Test sequence G13.488733
5.5 Ribbed poly V-belt G14.12289
5.6 Tensioner G14.12442
5.7 Starter cup G14.12564
6. Clutch G14.1086591
6.1 Belt pulley / clutch drum G14.12865
6.2 Studs for securing the cast arm with guard G14.12966
7. Shortblock G14.13016
7.1 Muffler / spark arresting screen G14.13024
7.2 Leak testing G14.13150
7.2.1 Preparatory steps G14.13176
7.2.2 Vacuum test G14.13271
7.2.3 Pressure test G14.13337
7.3 Oil seals G14.13431
7.4 Removing and installing the shroud G14.13671
7.5 Cylinder G14.13898
7.6 Crankshaft G14.14252
7.6.1 Removal and installation G14.14256
7.6.2 Grooved ball bearing / crankcase G14.14800
7.7 Piston G14.14990
7.7.1 Removal G14.14994
7.7.2 Installation G14.15074
7.8 Piston rings G14.15243
7.9 Decompression valve G14.15306
8. Ignition system G14.15358
8.1 Ignition module G14.15397
8.1.1 Removal and installation G14.15436
8.2 Ignition timing G14.15627
8.3 Testing the ignition module G14.15643
8.4 Spark plug boot G14.15776
8.5 Flywheel G14.15900
8.6 Short circuit wire / switch G14.16005
8.6.1 Testing G14.16009
8.6.2 Removal and installation G14.16080
8.7 Troubleshooting, ignition system G15.187863
9. Rewind starter G16.77686
9.1 General G16.77692
9.2 Removal and installation G16.77728
9.3 Pawl G16.77768
9.4 Rope rotor G16.77832
9.5 Starter rope / starter grip G16.77985
9.6 Tensioning the rewind spring G16.78152
9.7 Replacing the rewind spring G16.78271
10. Repairing the AV system G16.78464
10.1 AV spring on the handlebar G16.78480
10.2 AV spring in the support G16.78605
10.3 AV spring at the bottom of the crankcase G16.1086951
10.4 AV spring on the carburetor G16.78773
10.5 Handlebar G16.78864
10.6 Rubber buffers / support G16.79044
11. Actuating levers G16.79244
11.1 Switch shaft / choke lever G16.79250
11.1.1 Switch shaft, removal and installation G16.79296
11.2 Throttle trigger / trigger interlock, removal and installation G16.79445
11.2.1 Choke lever / holder, removal and installation G16.79571
12. Fuel system G16.1087537
12.1 Air filter G16.1087543
12.2 Carburetor, removal and installation G16.79723
12.2.1 Leakage testing G16.79928
12.3 Repairing the carburetor G16.80039
12.3.1 Metering diaphragm G16.80043
12.3.2 Inlet needle G16.80186
12.3.3 Fixed jet G16.80290
12.3.4 Pump diaphragm G16.80325
12.3.5 Air valve G16.80464
12.3.6 Choke shaft / choke shutter G16.80767
12.3.7 Throttle shaft / throttle shutter G16.80950
12.3.8 Adjusting screws G16.81247
12.4 Carburetor adjustment G16.81375
12.4.1 Basic setting G16.81379
12.4.2 Standard setting G16.81441
12.5 Choke rod and throttle rod G16.81592
12.6 Intake elbow, removal and installation G16.81693
12.6.1 Impulse hose G16.81920
12.7 Tank vent G16.81968
12.7.1 Testing G16.81970
12.7.2 Removal and installation G16.82108
12.7.3 Manual fuel pump G16.82168
12.8 Fuel Intake G16.82317
12.8.1 Pickup body G16.82321
12.8.2 Fuel hoses G16.82404
12.8.3 Fuel tank filler cap G16.82603
12.9 Tank housing, removal and installation G16.1089111
13. Special tools G17.545556
14. Servicing accessories G18.169540

TS410 – 4238 107
TS420 – 4238 139

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